Wire terminals and lead connector devices



June 11, 1963 H, EGE

WIRE TERMINALS AND LEAD CONNECTOR .DEVICES Filed Deo. 27, 1960 INVENToR.czfz ffy@ BY 3,093,433 WiRl TENALS AND LEAD CONNECTOR DEVICES Hans Ege,Chicago, Ill., assigner to UnderwritersSafety Device Company, Chicago,lll., a corporation of Illinois Filed Dec. 27, 1960, Ser. No. 78,380 6Claims. (Cl. 339-95) The present invention relates to terminal means ofnew and improved design providing for improved efficiency in making wirelead connections. More specifically, the invention is directed to wirelead terminals and disconnect devices particularly adapted for use -ininterconnecting terminal blocks, the terminals being of new and improveddesign providing for unique wire lead connection thereto in a new andimproved manner.

It is an object of the present invention to provide a new and improvedwire lead connection arrangement for use in attaching a wire lead to aterminal.

Another object is to provide new and improved terminal devices for wirelead connection thereto, the terminal devices being particularly'adapted for use in terminal blocks and further including means wherebya plurality of terminal blocks may be interconnected in ready disconnectrelation by use of said terminal devices.

Still a further object is to provide a new and improved wire leadconnector device which functions as a terminal for the lead, theconnector device being formed with cooperating lead locking strip meanswhich receive a wire lead therebetween and cooperatively lock andterminate the same merely upon insertion of the wire lead between thelocking means, the termination and connection provided by the devicebeing of a suliiciently pennanent nature to provide for good electricalconductive contact between the lead and connector device.

Still `another object is to provide a newand improved terminal for wirelead connection thereto, the terminal including confined lead connectormeans of new and improved design which are capable of mechanicallylocking and electrically terminating a wire lead merely upon theinsertion of said lead into the terminal and connector means.

Other objects not specifically set forth will become apparent from thefollowing detailed description of the present invention made inconjunction with the accompanying drawing wherein:

B1G. 1 is a side elevation of a pair of interconnected terminal blocksmaking use of the new and improved lead connector and blockinterconnection means Vof the present invention;

FIG. 2 is an end elevation of the interconnected blocks of FIG. l;

FIG. 3 is a plan view of the interconnected blocks of PEG. l;

FIG. 4 is a bottom plan view of one of the blocks of the unit of FlG. 1taken generally along line 4-,4 therein and further illustrating theblock interconnection means in section;

FIG. 5 is an enlarged cross sectional viewof the terminal block assemblyof FIG. l taken generally along line 5-5 in FIG. 3;

FIG. 6 is an enlarged perspective of female-type wire lead connectorsforming a part of the present invention; and

FiG. 7 is an enlarged perspective of `a male-type lead connector forminga part of the present invention.

rFlGS. l and 2 illustrate a pair of terminal blocks 1t) and 11 ininterconnected relation, each of these blocks being formed from anysuitable material such as molded plastic and being provided internallythereof with recessed openings and grooves in which the terminal stripsand diste States are Nice connect terminals of the present invention aremounted. The interconnected faces of the blocks '10 and 11 are eachprovided with a cover plate 12 and .13, respectively, formed from`insulating material and suitably attached to the blocks by fastenerssuch as rivets 14. The block 10 is provided with a pair of projectingmale plug members 15 in the form of prongs or blades for receiving in asuitable female socket member or receptacle in the known manner. The topblock 10 also carries a third .U-shaped guide prong 16 which functionsas a ground for the assembly and which is adapted to be received in asuitable recess in a female receptacle. The guide prong 16 as best shownin FIG. 3 is formed with a circular base portion 17 received in asuitable recess `1-8 in the top of the block 10 and secured therein lbya rivet 14.4 A ground connection to the rivet 14 or prong .16 can bereadily made in Iany suitable manner.

FIGS. 3 and 4 illustrate the top and bottom surfaces of the terminalblock 10. Referring to FIG. 3, the top surface of the terminal block 10is providedwith aplurality of circular openings 19 which extenddownwardly into the interior of the block 10 into communication withrectangnilar recesses 20- shown -in FIG. 4. The recesses 20 extendthrough to the bottom face of the block `10 and are at least partiallyclosed off by the cover plate 12. Received in the recesses 20 are aplurality of wire lead connectors 21 in the form of terminal strips. Themale plug blades 15 are in the form of metallic strips which extend intothe block 10 through suitable end face openings therein and throughslots 22 into communication with the lead connectors 21 for attachmentthereto in a manner to be described. The outer ends of the blades 15 arereversely folded in the known manner. n

Referring particularly to FIG. 5, the specific manner in which theblocks 10 and 1\1 are interconnected for ready disconnection is bestillustrated. The block 11 is constructed similarly to the block 10 withthe exception that no recesses or openings are provided in the block 11for the receipt of male plug blades. Thus for ease of identification ofsimilar parts, the recesses and openings `in the block 1d similar tothose described in conjunction with the block 10 are identified by`primed reference numerals. The rectangular recesses 20' of the block 11have received therein a plurality of male-type wire lead connectors 23which function as disconnect terminals. Each of the cover plates .12 and13 are provided with aligned rectangular openings 24 through which theblock connection means forming a part of the male connectors :23 extendinto block interconnecting engagement with portions of the femaleconnectors 21.

FIG. 6 illustrates the structural features of the femal lead connectors21 .and their connection with a male plug member 15. Each connector 21is formed from a single strip of electrical current conductive resilientmaterial. The strip is folded and shaped to define a lead 'connectionportion of Vgenerally rectangular outline. As illustrated in FIG. 6, thebottom end portion 25 is'integrally formed with upstanding side portions26 and 27 which parallel one another in an upwardly direction. The sideportions 26 and 27 are in the form of resilient strip means with theupper end of the strip means 26 being formed with a right angled flangeportion 28 which constitutes the opposite end surface of the connector.The upper edge of the side strip 27 terminates short of the free edge ofthe top flange portion 28 and has integrally formed therewith adownwardly and inwardly inclined wire lead lockingilange 29. This flangeextends diagonally toward the inner surface portion of the side strip 26into close proximity to a base marginal portion of a wire lead lockingrib 3l). The rib is formed in the side strip 26 and extends transverselythereof between the side margins. The rib 30i is in the form of a deepgenerally U or V-shape and, in effect, provides a projection extendinginto the interior of the connector 21 for cooperative functioning withthe locking flange 29. The end wall 25 of the `connector 21 constitutesa disconnect terminal means having a centrally located, generallyrectangular aperture 31 therethrough to receive a male connector 23 inthe manner to be described. The opposite end flange 28 constitutes awire lead insertion flange `and is provided with a centrally locatedaperture 32 through which a wire lead is inserted into the interior ofthe connector 21.

As more specifically shown in FIG. 6, a pair of female lead connectors21 are formed from a single metallic strip. This is accomplished byintegral formation of the end portions 25 of each of the connectors 21as a continuous base strip. However, it will be understood that eachconnector 21 may be readily formed as a single element and referring ttoFIG. 5, the outermost connectors 21 are single members. The secondfemale connector 21 of FIG. 6 is of the same construction as theconnector described above and the innermost end of the male blade isreceived interiorly thereof. As previously described, the blade 15 isformed from a at strip of metallic material and the innermost end of theblade is suitably attached to the connector 21 by a rivet 33 anchored inthe side strip 27 thereof. The outer end portion of each blade 15 isslightly oiset from the inner end portion thereof to provide foradequate spacing of the blades as shown in FIG. 4 for insertion in afemale receptacle.

FIG. 7 illustrates a male-type lead connector 23 formed from a singlestrip of electrical current conductive metallic material. The connector23 includes a pair of parallel side strip portions 34 and 35 the bottommargin of the side strip 34 as viewed terminating in a reversely foldedwire lead locking ange 36 which extends inwardly and upwardly into theinterior of the connector. The bottom edge of the strip 35 as viewedterminates in a right angled wire lead insertion flange 37 which isprovided with a central aperture 38 through which a wire lead isreceived into the interior of the connector. The upper ends of the sidestrips 34 and 35 are each provided with right angled, inwardly directedshoulder portions 39 which are integrally joined through an upwardlyprojecting prong-like member 40 which is similar to a blade of a maleplug and which is dimensioned to be frictionally received through adisconnect terminal opening 31 of a female-type connector 21. The bladeportion 40 is shaped with an enlargement toward the outer end thereof ofgenerally oval outline and the material used is adequately resilient toprovide for tight confinement of the blade 40 in an opening 31 of aconnector 21. The side strip 35 is formed with an inwardly projectingrim or rib 41 which cooperates with the lead locking flange 36 in amanner to be described, the free end of the locking ange 36 terminatingin close proximity -to a base margin of the rib 41.

FIG. 5 illustrates operative use of the connectors 21 and 23 in theterminal block assembly previously described. Referring to the pair offemale connectors 21 located to the left as viewed in FIG. 5, suitablewire leads including insulation :covering 42 and at least one strand ofwire 43 are inserted in each of the openings 19 of the block 10. Theinsulation 42 is received well into the opening 19 and the wire lead 43projecting from the end thereof is inserted through the aperture 32 of alead guide flange 28 of a connector 21. The aperture 32 is preferablyflanged as best illustrated in FIG. 5 to eliminate any sharp surfacesthat might damage the wire. Furthermore, it should be understood thatwhere a wire of smaller diameter is used, the entire wire including theinsulation thereof may be actually received through an opening 32. 'I'hewire lead is forced into the opening 19 to an extent that the bare wireend 43 contacts the adjacent surface of a locking ange 29 and is guidedby the same over the free edge thereof into abutment with the adjacentbase of the cooperating locking rib 30. `Continued forceful insertion ofthe bare wire 43 results in the same moving between the locking flange29 and over the rib 30. During this movement the locking flange 29 isactually bent slightly away from the locking rib 30 due to theresilience of ythe material from which it is formed. Following adequateinsertion of the wire lead 43 between the cooperating locking elementsof the connector 21, the insertion force is discontinued and the lockingflange 29 functions to clamp or grip the bare lead 43 between its freeedge and a surface portion of the rib 30.

To aid in guiding the bare lead 43 into position between the free edgeof the flange 29 and rib 30, the flange 29 is preferably dished orprovided with a bare lead contacting concave surface 44. With thelocking flange 29 thus being transversely arcuate, the bare lead 43 isguided thereon for substantial central locking between the flange andthe rib. The locking flange 29 is preferably inclined relative to theside strip 27 of which it forms a part to establish an yangle ofapproximately 40 therebetween. With the resilient locking of the barewire lead 43 between the flange and the rib, the conductor cannot tbereadily withdrawn and an eilicient electrical connection is made.Actually, with the structural features described, it has been found thata very substantial amount of force must be applied to the conductor toseparate the same from the connector. Such force greatly exceeds lthatwhich would normally occur in use of the terminal blocks and is of suchmagnitude that would even result in separation of a standard solderedconnection.

Referring to the male lead connectors 23, the two connectors shown inthe block 11 to the left as viewed in FIG. 5 have received therein barelead wires 43 which are clamped in the same manner as previouslydescribed. Thus the male connectors 23 function in the same manner asthe female connectors 21 in providing an insertion type connection of alead wire. The apertures 38 of the lead insertion flanges 37 arepreferably defined by a tubular ange projecting into the interior of thedevice to protect the bare wire or insulation which might be insertedtherethrough.

'Ihe male-type blade 40 of the male connectors 23 extend through theopenings 24 in the cover plate 13 of the terminal block 11 and projectsubstantially therefrom. When the terminal block 11 is connected withthe terminal lblock 10 as shown in FIG. 5, the blades 40 are insertedthrough the aligned openings 24 of the cover plate 12 and are forcedinto the apertures 31 of the end portions 25 of the aligned femaleconnectors 21. The apertures 31 are preferably provided with inwardlydirected flange portions 45 which function to guide .the blades 40,provide increased surface contact therewith for ecient electricalconduction, and function to wipe the same for good electrical contact.The apertures 31 and the blades 40 are -dimensioned so that the bladesare actually compressed and frictionally held in the apertures to thusprovide for an adequately strong connection between the blocks 10 and11. With this arrangement the blocks may be readily disconnected andreconnected at will.

From the foregoing description it will be appreciated that a lead wireterminal connection can be quickly and eiciently made by use of thespecial connectors or terminals of the present invention. The connectionarrangement completely eliminates the necessity of soldering a bare leadto a terminal, loosening and tightening terminal screws or the like, andseparate manual movement of resilient terminal parts during lead wireinsertion. The connectors are simply constructed and can be economicallymanufactured either as single terminals or as a series of integrallyinterconnected terminals.

Obviously cer-tain modifications and variations of the invention ashereinbefore set `forth may be made without departing from the spiritand scope thereof, 'and therefore only such limitations should beimposed as are indicated in the appended claims.

I claim:

1., A terminal for lead connection thereto, said terminal being formedfrom a single strip of electrical current conductive resilient material,said strip centrally thereof being reversely folded to define -a leadconnection portion of generally rectangular outline, said leadconnection portion at one end thereof forming a disconnect terminalmeans, the other end of said lead connection portion including a rightangled apertured lead insertion flange constituting one end of saidsingle strip and a diagonally inwardly `folded lead locking iiangeconstituting the other end of said single strip, said locking flangeIbeing located inwardly of said lead insertion iiange with the free endthereof being in close proximity to a side marginal base of a leadlocking rib formed in said strip inwardly of said lead insertion flange,said locking rib being formed from an inwardly offset transverse portionof said strip and projecting into said lead connection portion forcooperative functioning with said locking flange in resiliently engaginga lead therebetween which lead is inser-ted into said lead connectionportion through the yaperture of said lead insertion flange.

2. The terminal of claim 1 wherein said disconnect ter minal means-constitutes a right angled centrally apertured area adapted forconnection with a male-type terminal means.

3. The terminal of claim \1 ywherein said disconnect terminal means isin the form of a male-type projection having outwardly bowed strip`portions defining the same for resilient insertion in a female-typeterminal means.

4. The terminal of claim 1 wherein said locking iian-ge denes an `angleof approximately 40 with that portion of said strip from which it isformed.

5. A lead terminal for lead connection thereto, said terminal beingformed from .a single strip of electrical current conductive resilientmaterial, said strip centrally thereof being reversely folded to definea lead connection portion of generally rectangular outline, said leadconnection portion at one end thereof forming a disconnect terminalmeans, the other end of said lead connection portion including a rightangled apertured lead insertion iiange constituting one end of saidsingle strip and a diagonally inwardly `folded lead locking iiangeconstituting the other end of said single strip, said locking ii-angebeing located inwardly of said lead insert-ion flange with the free endthereof being in close proximity to a side marginal base of a leadlocking rib formed in said strip inwardly of said lead insertion flange,said locking rib extending transversely of said strip` and projectinginto said lead connection portion for cooperative functioning with saidlocking flange in resiliently engaging a lead therebetween which lead isinserted into said lead connection portion through the aperture `of saidlead insertion flange, said locking ilange being transversely bowed topresent a concave yface to a lead vduring insertion thereof and definingan angle of approximately with that portion o-f said strip from which itis formed.

6. The terminal of claim 5 wherein said disconnect terminal means is inthe form of a male-type projection having `outwardly bowed strippontions defining the same for resilient insertion in a female-typeterminal means.

References Cited in the le of this patent UNITED STATES PATENTS2,725,544 Strange Nov. 29, 1955 2,745,081 Oiferman May 8, E'19562,946,036 Bettencourt July Q19, 1960 2,968,780 Roswell Jan. l`7, 1961FOREIGN PATENTS 553,280 Great Britain May 14, 1943

1. A TERMINAL FOR LEAD CONNECTION THERETO, SAID TERMINAL BEING FORMEDFROM A SINGLE STRIP OF ELECTRICAL CURRENT CONDUCTIVE RESILIENT MATERIAL,SAID STRIP CENTRALLY THEREOF BEING REVERSELY FOLDED TO DEFINE A LEADCONNECTION PORTION OF GENERALLY RECTANGULAR OUTLINE, SAID LEADCONNECTION PORTION AT ONE END THEREOF FORMING A DISCONNECT TERMINALMEANS, THE OTHER END OF SAID LEAD CONNECTION PORTION INCLUDING A RIGHTANGLED APERTURED LEAD INSERTION FLANGE CONSTITUTING ONE END OF SAIDSINGLE STRIP AND A DIAGONALLY INWARDLY FOLDED LEAD LOCKING FLANGECONSTITUTING THE OTHER END OF SAID SINGLE STRIP, SAID LOCKING FLANGEBEING LOCATED INWARDLY OF SAID LEAD INSERTION FLANGE WITH THE FREE ENDTHEREOF BEING IN CLOSE PROXIMITY TO A SIDE MARGINAL BASE OF A LEADLOCKING RIB FORMED IN SAID STRIP INWARDLY OF SAID LEAD INSERTION FLANGE,SAID LOCKING RIB BEING FORMED FROM AN INWARDLY OFFSET TRANSVERSE PORTIONOF SAID STRIP AND PROJECTING INTO SAID LEAD CONNECTION PORTION FORCOOPERATIVE FUNCTIONING WITH SAID LOCKING FLANGE IN RESILIENTLY ENGAGINGA LEAD THEREBETWEEN WHICH LEAD IS INSERTED INTO SAID LEAD CONNECTIONPORTION THROUGH THE APERTURE OF SAID LEAD INSERTION FLANGE.